Transfer layer for absorbent article

Abstract

A composite particularly suited for use as a transfer layer in an absorbent article has a first layer comprising a formed film having a plurality of capillary-sized apertured protuberances and a plurality of two-dimensional drains, and a second layer in intimate contact with an apertured end of said capillary-sized protuberances and spaced from the first layer in a z-direction, the second layer is either a three-dimensional apertured formed film or a nonwoven web. In embodiments where the second layer is a three-dimensional formed film, the film contains a plurality of capillary sized protuberances that are of smaller diameter compared to the protuberances in the first layer and optionally also contains a plurality of drains, which can be either two-dimensional or three-dimensional, or combinations thereof.

The invention claimed is: 
     
       1. A formed film comprising:
 a plurality of capillary-sized protuberances extending in a z-direction from a female side of the formed film toward a male side of the formed film, wherein the plurality of capillary-sized protuberances comprise a diameter of between 50 microns and 400 microns at the female side of the formed film; 
 a plurality of two-dimensional drains formed between at least a portion of the plurality of capillary-sized protuberances at the female side of the formed film, wherein the plurality of two-dimensional drains lack a z-dimension beyond a nominal thickness of the formed film, and wherein the plurality of two-dimensional drains each comprise an average diameter greater than the diameter of the plurality of capillary-sized protuberances; and 
 a plurality of apertures defined by ends of the plurality of protuberances at the male side of the formed film. 
 
     
     
       2. The formed film of  claim 1 , wherein the average diameter is between 0.55 mm and 1.2 mm. 
     
     
       3. The formed film of  claim 1 , wherein the plurality of two-dimensional drains further comprise an average cross-sectional area greater than 0.2 mm 2 . 
     
     
       4. The formed film of  claim 1 , wherein a ratio of a radius of the plurality of two-dimensional drains to a radius of the plurality of capillary-sized protuberances is greater than 3:1. 
     
     
       5. The formed film of  claim 1 , wherein the plurality of capillary-sized protuberances are cone-shaped. 
     
     
       6. The formed film of  claim 1  further comprising an absorbent core adjacent to either the female side of the formed film or the male side of the formed film. 
     
     
       7. An absorbent article comprising:
 a transfer layer comprising a formed film having a plurality of capillary-sized apertured protuberances extending in a z-direction from a female side of the formed film toward a male side of the formed film, a plurality of two-dimensional drains formed between at least a portion of the plurality of capillary-sized protuberances at the female side of the formed film, and a plurality of apertures defined by ends of the plurality of protuberances at the male side of the formed film, wherein the plurality of capillary-sized protuberances comprise a diameter of between 50 microns and 400 microns at the female side of the first layer, wherein the plurality of two-dimensional drains lack a z-dimension beyond a nominal thickness of the formed film layer, and wherein the plurality of two-dimensional drains each comprise an average diameter greater than the diameter of the plurality of capillary-sized protuberances; and 
 a core adjacent to at least one of side of the transfer layer. 
 
     
     
       8. The absorbent article of  claim 7 , wherein the average diameter is between 0.55 mm and 1.2 mm. 
     
     
       9. The absorbent article of  claim 7 , wherein the plurality of two-dimensional drains further comprise an average cross-sectional area greater than 0.2 mm 2 . 
     
     
       10. The absorbent article of  claim 7 , wherein a ratio of a radius of the plurality of two-dimensional drains to a radius of the plurality of capillary-sized protuberances is greater than 3:1. 
     
     
       11. The absorbent article of  claim 7 , wherein the plurality of capillary-sized protuberances are cone-shaped. 
     
     
       12. The absorbent article of  claim 7  further comprising a topsheet. 
     
     
       13. The absorbent article of  claim 12 , wherein the transfer layer is positioned between the topsheet and the core. 
     
     
       14. The absorbent article of  claim 5 , further comprising a backsheet. 
     
     
       15. The absorbent article of  claim 14 , wherein the transfer layer is positioned between the core and the backsheet. 
     
     
       16. An absorbent article comprising:
 a topsheet; 
 a transfer layer adjacent to the topsheet, the transfer layer comprising a formed film having a plurality of capillary-sized apertured protuberances extending in a z-direction from a female side of the formed film toward a male side of the formed film, a plurality of two-dimensional drains formed between at least a portion of the plurality of capillary-sized protuberances at the female side of the formed film, and a plurality of apertures defined by ends of the plurality of protuberances at the male side of the formed film, wherein the plurality of capillary-sized protuberances comprise a diameter of between 50 microns and 400 microns at the female side of the first layer, wherein the plurality of two-dimensional drains lack a z-dimension beyond a nominal thickness of the formed film layer, and wherein the plurality of two-dimensional drains each comprise an average diameter greater than the diameter of the plurality of capillary-sized protuberances; and 
 an absorbent core adjacent to transfer layer opposite of the topsheet such that the transfer layer is positioned between topsheet and the absorbent core; and 
 a backsheet adjacent to the absorbent core opposite of the transfer layer such that the absorbent core is positioned between the transfer layer and the backsheet. 
 
     
     
       17. The absorbent article of  claim 16 , wherein the average diameter is between 0.55 mm and 1.2 mm. 
     
     
       18. The absorbent article of  claim 16 , wherein the plurality of two-dimensional drains further comprise an average cross-sectional area greater than 0.2 mm 2 . 
     
     
       19. The absorbent article of  claim 16 , wherein a ratio of a radius of the plurality of two-dimensional drains to a radius of the plurality of capillary-sized protuberances is greater than 3:1. 
     
     
       20. The absorbent article of  claim 16 , wherein the plurality of capillary-sized protuberances are cone-shaped.